Volume 02 Issue 04-2022
1
American Journal Of Applied Science And Technology
(ISSN
–
2771-2745)
VOLUME
02
I
SSUE
04
Pages:
01-11
SJIF
I
MPACT
FACTOR
(2022:
6.
108
)
OCLC
–
1121105677
METADATA
IF
–
5.582
Publisher:
Oscar Publishing Services
Servi
ABSTRACT
The article provides knowledge and skills on the rational use of equipment of machine tools, a single system of pre-
scheduled repairs to extend the service life of metal cutting machines, an inspection of machines, wear of parts and
components and modern methods of their restoration, the formation of appropriate knowledge, skills and
competencies. In particular, at present, the enterprises producing parts for the local automotive industry, operating
in the regions of the Republic, produce products on large press tandem lines and small press machines. Thousands
of expensive press moulds are imported from the world's largest machine-building companies, and their
maintenance and repair processes are very expensive for localized companies. If there are small defects, problems
or repairs in the parts of the press moulds, it is necessary to carry out urgent repair of the mould with the
participation of the enterprise and the main manufacturer. There is a solution to the problem of forming the current
and capital repairs of small and large press-moulding equipment, the restoration and production of parts and other
elements.
KEYWORDS
Press moulds, mould emergency repair, unified system of scheduled repairs, local automotive, maintenance and
repair.
Research Article
TECHNOLOGY OF REPAIR OF PRESS MOLDS FOR PRODUCTION OF
MACHINE PARTS FROM STEEL COILS, ALUMINUM ALLOYS
Submission Date:
April 08, 2022,
Accepted Date:
April 10, 2022,
Published Date:
April 18, 2022
Crossref doi:
https://doi.org/10.37547/ajast/Volume02Issue04-01
R.M. Tadjikuziyev
Senior Lecturer, Department Of Mechanical Engineering And Automation, Fergana Polytechnic Institute,
Fergana, Uzbekistan
Journal
Website:
https://theusajournals.c
om/index.php/ajast
Copyright:
Original
content from this work
may be used under the
terms of the creative
commons
attributes
4.0 licence.
Volume 02 Issue 04-2022
2
American Journal Of Applied Science And Technology
(ISSN
–
2771-2745)
VOLUME
02
I
SSUE
04
Pages:
01-11
SJIF
I
MPACT
FACTOR
(2022:
6.
108
)
OCLC
–
1121105677
METADATA
IF
–
5.582
Publisher:
Oscar Publishing Services
Servi
INTRODUCTION
Maintenance and repair of parts and components are
carried out in specially equipped mobile or stationary
workshops. These workshops will be equipped with
the necessary equipment and spare parts, and all the
conditions for the work of workers (heating and
cooling systems of the building and the mobile
workshop, washing and dining rooms) will be created
[1-4]. The workshop has special buildings for
maintenance and repair work. Indoor washing;
division into parts and components (including those
that are suitable or unsuitable for restoration);
mechanical (this shop is mainly equipped with various
machines for cutting, sawing, drilling, tooth
extraction,
grinding,
grinding
and
other
metalworking); metal smelting and heat treatment;
welding; diagnostics; collect hardening; There will be
painting shops. Organizations with a fleet of
construction and reclamation machines will have a
base with their own machine maintenance and repair
shop [5-11]. The base area is surrounded by a wall,
including a residential and administrative building, a
workshop, a warehouse of petroleum products built
in compliance with fire safety and their storage
containers, a device consisting of fire-fighting
materials and containers, and fuel. - Lubricant pouring
station, car storage room and areas, parking area for
repaired cars, storage area for raw materials, external
control and washing areas of the machine [12-19]. The
base will also have equipment with special
prefabricated measuring instruments for maintenance
and repair of field machines, various equipment, and
portable technical equipment equipped with a set of
keys of different sizes.
MATERIALS AND METHODS
The purpose of the work is to improve the basic types
of automatic lines, robotic manipulators, conveyors
and unique equipment, their components, parts repair
technology,
post-repair
assembly
technology,
equipment improvement, installation, inspection and
maintenance,
increase
training.
Theoretical
knowledge of basic devices, important parts, control
of automatic equipment, including: digital software
and microprocessor control systems, the use of
industrial robots and pre-training on how to increase
their accuracy and productivity [20-27]. The subject
"Repair
and
maintenance
of
technological
equipment" for students to know and use by
professors and teachers in scientific work in the
framework of the tasks performed in the process of
manufacturing enterprises operating in the region:
know the development trends, types, structure,
principles of operation, basic structures, essential
parts, use of technological equipment and
methods of maintenance and repair for their
rational use, rational use of technological
equipment used in machine-building enterprises;
Professors and students of engineering and
technology to ensure their optimal technical and
economic
performance
in
the
use
of
technological equipment, the calculation of their
service life between repairs, the types of repairs,
and the optimal conditions under certain
production conditions. Ability to correctly
determine the geometric proportions of the
design parameters of process equipment and
industrial robots to ensure the performance and
operating modes;
Technical and economic and constructive analysis
of technological equipment and industrial robots
produced
and
used
by
the
student,
determination
of
optimal
indicators
and
operating modes for their accurate and efficient
use, calculation and design of workflows on
technological
equipment,
knowledge
of
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METADATA
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Publisher:
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Servi
automated technological equipment must be
qualified to perform the work.
Modern machine building is characterized by the
complexity of product design and the rapidly
changing range of products, as well as the short
duration of production. Under such conditions, it is
necessary to accelerate production and increase its
efficiency, as well as ensure the competitiveness of
the product [28-32]. Therefore, the organization and
conduct of maintenance and repair work on a
scientific basis for the efficient use of high-
performance
and
high-precision
technological
equipment is one of the most pressing issues in the
effective use of expensive technological equipment.
Repair and maintenance of metal cutting machines.
Press moulds are complex high-tech equipment of
injection moulding technology. Timely diagnosis and
maintenance of moulds are the keys to the successful
operation of the enterprise. Repair of press moulds,
repair of moulds for making parts from aluminium
alloy. If there are small defects in the press-mould
parts, we must carry out an emergency repair of the
mould in the presence of the customer. Forming and
restoring press moulds for moulding and other
equipment elements in the production of parts. Using
MikroSpot technology, the metal coating (welding
with TIG gas-shielded filler wire) allows for practically
correcting all defects in the press-mould parts that
occur during the operation of the equipment. When
repairing a mould with a surface, we select the fillings
that match the metal brand and allow its hardness to
be maintained. The advantage of welding with a non-
consumable TIG electrode is the very high quality of
the weld, the absence of slag, and the practical
absence of slag. This method of welding and surface
coating is universal, allowing it to work with a variety
of materials and many types of metal compounds
(Figure 1-8).
Figure 1. Coating, expansion of the
monolithic sector.
Figure 2. Restored view of the sector.
The hard-coated sector is machined on a DPS machine. View of the post-restoration barrier sector.
Volume 02 Issue 04-2022
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METADATA
IF
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Publisher:
Oscar Publishing Services
Servi
Figure 3. Cracks in matrices.
Figure 4. This matrix is a view of the
worn edges of the punched plates of the
Puanson press mould.
Figure 5. Repair of press-mould dies by
filling and welding
Figure 6. Detection of cracks in the
corners of the press-mould matrix
Figure 7. Welding on the outside of the
press mould
Figure 8. The technology of filling of
forming surfaces by filling methods
If the repair of Press-molds is carried out in accordance
with the requirements of 10-point series repair, the
most complex mould repair will be carried out with high
quality. For complete diagnostics or information on the
repair of moulds (and other technical equipment):
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METADATA
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Servi
1). Press-mold testing is carried out on special TITA test
equipment. This allows the detection and formation of
casting defects and mould performance defects. Based
on these indicators, plan the necessary repairs,
indicating the cost and timing of repairs on the initial list
of defects.
2). Disassembly (disassembly) and diagnostics of
elements, parts, and plates of the press mould, which is
planned to be repaired. Approval of the repair list
indicates the price and duration.
3). Agree on the types of methods of repair of the press
mould, current and capital repairs, agree on the
possible results of the work, in particular:
Operation and maintenance of the mould;
Injection quality.
4). Carry out a visual inspection of all elements, parts,
and plates of the mould, if possible and, if necessary,
measure the parts and elements of the mould block. If
necessary, agree in advance on a list of additional
repairs, indicating the price and duration.
5). Carrying out repair work, agreeing on the current or
overhaul options of the mould, agreeing on the possible
results of this work, in particular: the performance of
the mould, the quality of the casting.
6). Carrying out repair work, and assembling the mould.
7). Coordinate and remedy deficiencies if defects are
identified during the block assembly process.
8). Press-mold testing in TITA laboratory device.
9). Processing of press mould and casting defects
identified during mould testing.
10). After the repair of the press-mould defect, the
mould is re-tested on the TITA device and the results
are diagnosed.
Accurate execution of press moulds in the sequence of
diagnostics and repair of the mould, detection and
elimination of defects in all elements, parts, and plates
of the moulds, the most positive results can be achieved
in high-quality and efficient repair work.
Prophylactic maintenance of press moulds of structural
complexity. The moulds must undergo maintenance and
scheduled warning repairs. The service life of moulds
depends in many respects on the current service and
qualifications of the operator, timely lubrication,
elimination of minor defects, timely grinding of
scratches, preventive inspections and periodic repairs
[33-36].
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Servi
Figure 9. External inspection of forming joints and press-mold parts
Figure 10. Complete disassembly, inspection, and inspection of all assembled parts
Press mould maintenance and repair list. During
operation, the press moulds must undergo periodic
maintenance and scheduled notification repairs (DNR).
The DNR system for presses and castings for the
production of plastic and steel sheet products is subject
to organizational and technical measures for the
control, maintenance and all kinds of repairs of moulds.
The DNR system includes the following basic types of
mould maintenance:
preventive inspection and maintenance of press
moulds;
current repairs;
medium and capital repairs.
Preventive inspection and preventive maintenance.
Depending on the scope of work, the scope of
work and the implementation of the work,
preventive work is divided into the following types:
Inter-shift maintenance, depending on the
operation of the press moulds performed during
the entire shift;
maintenance after removal of the mould from the
equipment, before sending it to the warehouse;
Maintenance of each shift without removing the
moulds from the equipment includes:
check the fastening and centring of the press
mould on the equipment, tighten the bolts if
necessary;
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IF
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Publisher:
Oscar Publishing Services
Servi
checking the mould, adjusting and lubricating the
guide elements;
cleaning holes from waste;
inspection of plates (pushers, rods);
check the heating plates, replace if necessary or
fasten the terminal block of the terminal, replace
the heaters;
check the surface of the parts of the press-mould
layer;
check the smooth movement of the moving parts
of the mould, lubricate the moving parts;
ensure the normal operation of other parts of the
press mould and components.
After removing the mould from the equipment
before sending it to the spare warehouse, its
maintenance includes:
external inspection of the form, detection,
cleaning, lubrication of defects during operation;
elimination of small defects, fastening, adjustment
of individual parts and devices;
replacement of easily replaceable disassembled
and fastened elements;
quality assessment of moulded products.
Current repairs. Maintenance is a type of light
repair in which the replacement of worn parts and
the restoration of the required surface coatings of
surface elements, as well as the cleaning and
casting system ensure the normal operation of the
press mould until the next scheduled repair. The
current repair of the mould includes:
partial disassembly and assembly of the press
mould by washing and cleaning individual parts;
replacement of pushers (their installation);
replacement of forming additives;
replacement of fastening bolts, checking of
threaded holes with holes (driving);
replacement of fastening screws and rods, pushers,
mechanisms of lateral movement signs;
elimination of rotating cones, precise adjustment
of drawing dimensions of individual inserts, die
elements and punches with a punch;
replacement of guideposts and bushings;
replacement of gear bushings for handles;
replacement of replacement signs;
replacement of rods, loading chambers;
Improving the injection system;
replacement of side handles, wedges, columns;
repair or replacement of mould heating system;
replacement of small sections;
replacement of fastening pins;
replacement of individual non-forming parts and
assemblies not listed above;
elimination of bumps, pits, creases in the waste
formations;
Installation and removal of the press mould on the
device.
If one or more of the listed works have been completed
and the total labour intensity of the repairs does not
exceed 20 standard hours, the current repair is
considered to have taken place.
Medium and capital repairs. Medium repair - a type of
planned repair in which partial dismantling of the
mould, overhaul of individual parts, replacement and
restoration of the main obsolete parts, restoration of
the coating and repair of the forming parts of the
moulds, their casting (presses) will be improved in
accordance with the requirements of the drawing. An
overhaul is a set of works, which includes the complete
dismantling of the mould, the replacement of all worn
parts with the restoration of all its performance,
provided by the technical conditions and drawings.
Medium or overhaul of press moulds includes:
complete or partial restoration of the coating of
press-mould parts;
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preparation and installation of moulding parts;
production of new punches and matrices;
Production of new clips and punch holders;
production of new plates and gaskets;
production of new slab stocks, slab pushers, other
parts of moving sleepers;
re-grinding of plates and proper adjustment of
pushers marks;
production of new additions;
Production of new clinics and side mechanisms;
restoration and installation of worn parts;
installation and adjustment of new restrictive
mechanisms;
return of works included in the current repair;
replacement of electric motors, reducers, bearings
and gears, hydraulic cylinders, etc.
Due to the complexity of the production of a new
press-mould, the labour productivity of the
restoration repair:
20-30% - for average repairs;
40-60% - is allocated for capital repairs.
Parts and equipment plates are made by milling the
surface of the surfaces. DPC milling equipment for
metalworking can be used to process parts of complex
configurations and plates of moulds, mould fillers,
calibrators, punches, and plates of other technological
tools and equipment. Drilling and planning operations
can be performed on these machines thanks to a special
tool mounted on the appropriate working heads. Digital
control of the equipment increases the productivity of
the machine several times, increases the accuracy of
processing, as well as precise placement of cutters and
other cutting tools. The use of hard-melting tools
(cutters, cutters) allows working on surfaces with a
hardness of up to 55 HRC.
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Publisher:
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Publisher:
Oscar Publishing Services
Servi
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11
American Journal Of Applied Science And Technology
(ISSN
–
2771-2745)
VOLUME
02
I
SSUE
04
Pages:
01-11
SJIF
I
MPACT
FACTOR
(2022:
6.
108
)
OCLC
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METADATA
IF
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Publisher:
Oscar Publishing Services
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